Miller BIG BLUE 400X PRO CE CAT/KUBOTA User manual

Miller BIG BLUE 400X PRO CE CAT/KUBOTA User manual
OM-281496D
2019−05
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welder/Generator
Big Blue 400 X Pro
®
CAT, Kubota
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Engine Drive
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. CAT Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Kubota Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
6
6
6
7
7
7
9
10
11
13
13
13
15
15
17
19
19
19
19
20
20
21
22
22
23
23
24
24
25
25
26
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
TABLE OF CONTENTS
5-7. Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Engine Fuel And Coolant Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting To Remote Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Dynamic Dig Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Lift-Arc TIG With Auto-Stop And Auto-Crater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Voltage/Amperage Control With 14-Pin Remote Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Operating Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Associating ArcReach Devices (ArcReach Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. CAT Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Kubota Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Checking Generator Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. CAT Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Kubota Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
26
27
28
28
29
29
30
30
31
32
33
34
35
36
36
37
38
39
40
41
42
43
43
44
45
45
46
47
48
49
49
50
50
51
52
53
54
56
56
59
59
60
64
64
65
66
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
907732010
907732011
907758
Product
Big Blue 400X Pro (Kubota)
Big Blue 400X Pro (Kubota) w/ ArcReach
Big Blue 400X Pro (CAT)
Council Directives:
• 2014/35/EU Low voltage
• 2014/30/EU Electromagnetic compatibility
·2000/14/EC & 2005/88/EC Outdoor noise
·Notified Body: AV Technology LTD, Unit 2 Easter Court, Europa Boulevard, Warrington, Cheshire, WA5 7ZB,
United Kingdom
·Conformity Assessment Procedure Followed: Annex VI, 2000/14/EC
·Technical Document Holder: Manufacturer
·Notified Body Evaluation Report No: GB/1067/5096/14 ISSUE 2
·Measured Sound Power level: 95 dB L WA
·Guaranteed Sound Power Level: 96 dB L WA
·Electric Power PeL : 9.6 kW
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
February 27, 2018
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
282222A
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
BIG BLUE 500 X PRO (PERKINS) CE W/ ARCREACH
BIG BLUE 400 X PRO (KUBOTA) CE
BIG BLUE 400 X PRO (KUBOTA) CE W/ ARCREACH
BIG BLUE 400 X PRO (CAT) CE
Stock Number
907761
907732010
907732011
907758
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory
Effects
10 cm
0.16
Health
Effects
10 cm
0.11
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.18
3 cm
0.10
3 cm
0.23
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
8 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
282267-A
Tony Samimi
Date tested:
2016-02-22
182 cm
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2018−06
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding
procedure are employed.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Manual before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-281496 Page 1
FLYING METAL or DIRT can injure
eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND
hazardous.
GASES
can
be
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
OM-281496 Page 2
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-281496 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Use only equipment suitable for operation on 60 or 50/60 Hz
power.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use correct procedures and equipment of adequate capacity to
lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-281496 Page 4
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
Have only qualified persons do battery charging work.
If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc,
make sure all accessories are off.
Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
Do not charge a frozen battery.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
HIGH PRESSURE FLUIDS can injure or kill.
Engine fuel system components can be under
high pressure.
Before working on fuel system, turn off engine
to release pressure.
If any fluid is injected into the skin or body seek medical help immediately.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with electronic equipment
perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-281496 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
Always start and operate the engine in a well−ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
For Standards regulating hydraulic systems, contact the National Fluid
Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
WI 53214 (phone: (414) 778-3344, website: www.nfpa.com).
Battery Service Manual, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.batterycouncil.org).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-281496 Page 6
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2018−06_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. L’électrode et le circuit de soudage sont
sous tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le
dévidoir, le logement des galets d’entraînement et
les pièces métalliques en contact avec le fil de
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
d’une tension de circuit−ouvert double.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
OM-281496 Page 7
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Arrêtez le moteur sur l’onduleur et déchargez les condensateurs
d’entrée conformément aux instructions du manuel avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en fil
de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
OM-281496 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).
Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
recouvrements et dispositifs de protection.
panneaux,
Arrêter le moteur avant d’installer ou brancher l’appareil.
Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-281496 Page 9
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes
industrielles et aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident matériel
ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air comprimé.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
OM-281496 Page 10
MÉTAL CHAUD provenant du découpage
ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
comprimé, les branchements et les flexibles en recherchant tout
signe de détérioration, de fuite et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES
PIÈCES
CHAUDES
peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement avant
d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Utiliser uniquement des équipements adéquats pour un fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-281496 Page 11
LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les
modèles.
Toujours porter une protection faciale, des gants en caoutchouc
et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles de
batterie, des câbles de chargeur de batterie (le cas échéant) ou de
batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si
l’appareil dispose d’une fonctionnalité de charge de batterie destinée à
cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres sources
d’inflammation doivent être maintenues à l’écart des batteries. Ces
dernières produisent des gaz explosifs en fonctionnement normal et
en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations sur
une batterie ou à proximité de celle−ci. Voir le manuel de service de
batterie (indiqué dans Normes de sécurité) pour plus d’informations.
Les opérations de charge de batterie ne doivent être effectuées que
par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge, débrancher
tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour
éviter un arc, s’assurer que tous les accessoires sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur
de batterie pour alimenter un autre circuit électrique basse tension ou
pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en l’absence
d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge ne
se touchent pas.
Ranger les câbles de charge à distance du capot, des portes et des
pièces mobiles du véhicule.
LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.
Les composants du système d’alimentation
peuvent contenir du carburant sous pression
élevée.
Avant d’intervenir sur le système d’alimentation de carburant,
arrêter le moteur pour dépressuriser le système.
En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
OM-281496 Page 12
Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles
que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation
de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Pour les moteurs diesel :
AVERTISSEMENT : les gaz d’échappement de moteurs diesel
vous exposent à des produits chimiques, reconnus par l’État
de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
Si la zone est fermée, diriger l’échappement vers l’extérieur.
Ne pas modifier ni altérer le système d’échappement.
Ne pas faire tourner le moteur au ralenti, sauf si nécessaire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West
Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
778-3344, site web : www.nfpa.com).
Manuel de service de batterie, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
1-312-245-1074, site Web : www.batterycouncil.org).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: par exemple, des restrictions
d’accès pour les passants ou une évaluation individuelle des risques
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-281496 Page 13
OM-281496 Page 14
Complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-281496 Page 15
Complete Parts List is available at www.MillerWelds.com
Do not weld on drums or any closed containers.
Safe16 2017−04
Do not remove or paint over (cover) the label.
Safe20 2017−04
Do not work on unit if engine is running. Stop engine first.
Safe21 2017−04
Do not smoke while fueling or if near fuel.
Safe22 2017−04
Stop engine before fueling.
Safe23 2017−04
Do not fuel a hot engine.
Safe24 2017−04
Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).
Safe25 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
=
Engine fuel plus flames or sparks can cause fire.
Safe45 2012−05
OM-281496 Page 16
Complete Parts List is available at www.MillerWelds.com
Never use generator inside a home or garage, even if doors and windows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2017−04
Hot muffler and exhaust pipe can cause severe burns.
Safe90 2017−04
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
Safe91 2017−04
3-2. Miscellaneous Symbols And Definitions
Some symbols are found only on CE products.
A
V
Amperage
Voltage
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Duty Cycle
n1
P1max
Hz
Rated Welding
Current
h
Direct Current
(DC)
X
I2
U2
U0
I
n
n0
Rated Load
Speed
Sound Level
Rated No-Load
Speed
Single Phase
Rated Idle Speed
Three Phase
Maximum Power
Consumption
Engine-Driven
3−Phase
Alternator with
Rectifier
Hertz
Contactor On
Hours
Negative
Positive
Conventional
Load Voltage
Seconds
Rated No-Load
Voltage (OCV)
Clock, Time
Switch
Current
Alternating
Current (AC)
Protective Earth
(Ground)
OM-281496 Page 17
Complete Parts List is available at www.MillerWelds.com
Circuit Breaker
Flux Cored Arc
Welding (FCAW)
Engine
Temperature
Output
Air Carbon Arc
Cutting (CAC-A)
Battery (Engine)
Off
Starting Aid
(Preheat)
Engine Belt
On
Engine
Supplementary
Protector
Increase or
Decrease of
Quantity
(Rotating)
Do Not Switch
While Welding
Remote
Read Operator’s
Manual
Welding (General)
Shielded Metal
Arc Welding
(SMAW)
Gas Metal Arc
Welding (GMAW)
OM-281496 Page 18
Engine
Engine
Idle (Slow)
Run (Fast)
Engine Start
(Engine RPM)
Manual Cleaning
Spark Arrestor
Air Filter
Check Air Cleaner
Check
Injectors/Pump
Check Valve
Clearance
Engine Stop
Certified/Trained
Mechanic
Engine Oil
Arc Control
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Fuel
USB
Filter
Push Button
Tungsten Inert
Gas (TIG) Lift Arc
Engine Coolant
Rotating Knob
And Push Button
Complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Weld, Power, And Engine Specifications
This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Generator Power
Rating
Engine
Caterpillar C1.5
Water-Cooled
Three-Cylinder 21.7
HP Diesel Engine
Kubota V1505 E3BG
Water-Cooled,
Four-Cylinder 20.2
HP Diesel Engine
Welding
Mode
Weld Output Range
Rated Welding
Output
Maximum
Open-Circuit
Voltage
Fuel
Capacity
400 A, 24 Volts DC,
100% Duty Cycle
Single-Phase,
10 kVA/kW, 84/42 A,
120/240 VAC, 60 Hz
CC/DC
20−400 A
CV/DC
14−40 V
350 A, 27 Volts DC,
100% Duty Cycle
84
11.5 gal
(43.5 L)
300 A, 32 Volts DC,
100% Duty Cycle
4-3. Dimensions, Weights, And Operating Angles
Dimensions
Height
32 in. (813 mm)
35.89 in. (912 mm)
(to top of lift eye)
Width
26 in. (660 mm)
(mtg. brackets turned in)
28.75 in. (730 mm)
(mtg. brackets turned out)
!
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth
56.25 in. (1429 mm)
!
A
56.25 in. (1429 mm)
Do not move or operate unit where it
could tip.
B
54.25 in. (1378 mm)
C
52.25 in. (1327 mm)
D
2 in. (51 mm)
E
26 in. (660 mm)
F
0.885 in. (22 mm)
G
27.77 in. (705 mm)
H
9/16 in. (14 mm) Dia.
4 Holes
G
A
B
C
30°
H
Front Panel End
Weight
No fuel:
CAT: 1010 lb (458 kg)
Kubota: 950 lb (431 kg)
With fuel:
CAT: 1092 lb (495 kg)
Kubota: 1032 lb (468 kg)
20°
D
30°
20°
F
E
Lifting Eye Weight Rating:
2000 lb (907 kg) Maximum
OM-281496 Page 19
Complete Parts List is available at www.MillerWelds.com
4-4. Environmental Specifications
A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used when welding outside during precipitation unless
sheltered.
IP23S 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ce-emc 3 2014-07
C. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
−40 to 104°F (−40 to 40°C)
−4 to 131°F (−20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
4-5. Duty Cycle And Overheating
1
1
100% Duty Cycle
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
This unit is rated for welding at
400 amperes, 24 volts DC
continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
WELD AMPHERES
400
300
200
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
266 504-A
OM-281496 Page 20
Complete Parts List is available at www.MillerWelds.com
4-6. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
DC VOLTS
80
60
MIN
300A
40
20
0
100
0
B. TIG Mode
200
300
DC AMPERES
400
500
100
DC VOLTS
80
60
40
MIN
20
0
0
300
100
200
300
MAX
400
500
400
500
DC AMPERES
C. MIG Mode
DC VOLTS
60
MAX
40
20
0
MIN
0
100
200
300
DC AMPERES
266200-A
OM-281496 Page 21
Complete Parts List is available at www.MillerWelds.com
4-7. AC Generator Power Curve
The AC power curve shows the
generator power in amperes.
AC VOLTS
280
270
260
250
240
230
220
210
200
190
180
0
10
20
30
40
50
AC AMPERES IN 240V MODE
266201A
4-8. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
266202A
OM-281496 Page 22
Complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welder/Generator
Airflow Clearance
18 in.
(460 mm)
Movement
18 in.
(460 mm)
18 in.
(460 mm)
OR
OR
18 in.
(460 mm)
18 in.
(460 mm)
Location/Mounting
2
Welding
Unit In
Place
Bolting
Unit In
2 Place
3
4
OR
OR
Tools Needed:
1
1
9/16 in.
Go
to MillerWelds.com for more
information on truck installations.
Movement
!
Do not move or operate unit where
it could tip.
See Section 4-3 for lifting eye rating.
Airflow Clearance
NOTICE − Do not install unit where air flow
is restricted or engine may overheat.
Location/Mounting
!
Always securely fasten welder/generator onto transport vehicle or
trailer and comply with all DOT and
other applicable codes.
install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
!
Do not weld on base. Welding on
base can cause fuel tank fire or explosion. Weld only on the four
mounting brackets or bolt unit
down.
NOTICE − Do not mount unit by supporting
the base only at the four mounting brackets. Use cross-supports to adequately support unit and prevent damage to base.
1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use cross-supports to support base. Secure unit with
mounting brackets.
3 1/2 in Bolt And Washer (Minimum −
Not Supplied)
4 3/8-16 x 1 in. Screws (Supplied)
To Bolt Unit In Place:
Remove hardware securing the four
mounting brackets to the base. Reverse
brackets and reattach to base with original
hardware.
Mount unit to truck or trailer with 1/2 in. (12
mm) or larger hardware (not supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at the four
mounting brackets.
OM-281496 Page 23
Complete Parts List is available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
rot_grnd2 2018−01 − 800652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
!
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
1
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
2
3
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-3. Installing Exhaust Pipe
!
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in.
Exhaust Pipe3 2018−01 / Ref. 803582
OM-281496 Page 24
Complete Parts List is available at www.MillerWelds.com
5-4. Connecting The Battery
−
+
Shown
with door
open and rocker
panel removed.
Tools Needed:
1/2 in.
Conn_Batt2 2014−11 / S-0756-C / 161-002
NOTICE − Lead acid batteries discharge
when stored in any temperature. Units that
are stored should have the battery
recharged every three months and before
being put into service. To preserve optimum battery performance and life,
recharge battery in storage when the
open−circuit voltage drops to 12.4 volts
DC when measured across the battery
terminals.
!
Connect negative (−) cable last.
NOTICE − Wait two minutes after engine
shutdown before disconnecting battery or
engine controller may be damaged.
Battery is accessed through the side door.
Connect battery, negative cable last.
Close side door.
Do not allow the battery cables to
touch opposing terminals. When connecting the battery cables attach the positive
(+) cable to the positive (+) battery terminal first, followed by negative (−) cable to
negative (−) battery terminal.
Never start the engine when the
cables are loose or poorly connected to
the battery terminals.
Never disconnect the battery while
the engine is running.
Never use a quick battery charger to
start the engine.
Do not charge battery with Engine
Control switch On.
Always disconnect the negative (−)
battery cable before charging battery.
5-5. CAT Engine Oil Prestart Information
Check oil with unit on level surface.
If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Full
907 427-6
OM-281496 Page 25
Complete Parts List is available at www.MillerWelds.com
5-6. Kubota Engine Oil Prestart Information
Check oil with unit on level surface.
If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Full
5-7. Engine General Information
Check all engine fluids daily.
Engine must be cold and on a level surface.
Automatic Shutdown System
Automatic shutdown system stops engine
if oil pressure is too low or coolant temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil
level often and do not use the oil pressure shutdown system to monitor oil
level.
Run-In
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 11.
NOTICE − Diesel engines in Miller equipment are meant to operate optimally at
moderate to rated load. Light or no load
may cause wetstacking or engine damage.
Cold Weather
To improve cold weather starting:
Use Preheat switch (see Section 6-1).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 8-3).
Use engine block heater if applicable
(see Section 6-10).
Gen_engine1 2012−04
OM-281496 Page 26
Complete Parts List is available at www.MillerWelds.com
5-8. Engine Fuel And Coolant Prestart Information
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Diesel
Engine stops
if
fuel level is low.
Coolant Recovery Tank
Hot
Full
Capacity:
6 qt (5.7 L)
Cold
Full
Fuel/Coolant_engine1 2012−04 Ref: 907 427−6−2
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Add fresh diesel fuel before starting (see
engine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
Coolant
Check coolant level in radiator before start-
ing unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34°F (−37°C). Add antifreeze to mixture if using the unit in temperatures below −34°F (−37°C).
Keep radiator and air intake clean and free
of dirt.
NOTICE − Incorrect engine temperature
can damage engine. Do not run engine without a properly working thermostat and radiator cap.
OM-281496 Page 27
Complete Parts List is available at www.MillerWelds.com
5-9. Weld Output Terminals
2
1
Ref: 263 480-A
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
Negative (−) Weld Output Terminal
Positive (+) Weld Output Terminal
1
2
5-10.
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal
on right and work cable to Negative (−) terminal on left.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select
type of weld output (see Section 6-3).
Connecting To Weld Output Terminals
Tools Needed:
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
1
6
Stop engine.
!
Do not place anything between weld
3/4 in.
3
!
2
1
Correct Weld Cable Connection
2
Incorrect Weld Cable Connection
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
4
5
803 778-B
OM-281496 Page 28
Complete Parts List is available at www.MillerWelds.com
5-11. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
1/0 (60)
1/0 (60)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
5-12. Connecting To Remote Receptacle
Socket*
Socket Information
Not all models have contactor control. See description of front panel controls and
circuit diagram.
24 VOLTS AC
*The remaining
sockets are not
used.
Accessories depend
on unit capabilities.
REMOTE
OUTPUT
CONTROL
A
24 volts AC. Protected by supplementary protector.
B
Contact closure to A completes 24 volt AC contactor
control circuit.
C
Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
G
Circuit common for 24 volt AC circuit.
OR
Rmt14_1 2010−04
NEUTRAL
OM-281496 Page 29
Complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATING WELDER/GENERATOR
6-1. Front Panel Controls (See Section 6-2)
6
8
12
9
7
10
13 14
4
5
3
1
2
11
Ref. 275308-B
OM-281496 Page 30
Complete Parts List is available at www.MillerWelds.com
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
4
1
Use switch to energize starting aid for cold
weather starting (see starting instructions
following).
Notifies user that engine oil service is due.
Upper LED illuminates when engine oil
change hours are between 49−1. Lower LED
illuminates when oil change hours are 0 or
less.
2
Weld Controls
Preheat Switch
Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed at no load and weld speed with load
applied.
To check engine hours when engine is
not running, turn Engine Control switch to
Run position. To check remaining oil
change hours when engine is not running, turn Engine Control switch to Run/
Idle position.
5
Engine Service Indicator Lights
Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
When a remote control is connected to the
Remote receptacle, the Auto Remote Sense
(ARS) feature automatically switches voltage/amperage control to the remote control
(see Section 6-9).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage
settings.
operation. Service Menu will time out after 5 seconds of inactivity.
Weld Meters
Weld meters also work in combination to
display troubleshooting error codes (see
Section 8-13).
8
DC Voltmeter
Voltmeter displays preset voltage (GMAW/
FCAW welding) with contactor off, and actual
output voltage with the contactor on. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due
to resistance of cable and connections.
To set voltage, turn Process/Contactor switch
to GMAW or FCAW position. Turn V/A control
until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter
displays average weld voltage and then defaults to preset voltage.
For
best performance when welding
above 300 amperes, place Engine Control switch in Run position.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and
amperage.
9
NOTICE − Diesel engines in Miller equipment
are meant to operate optimally at moderate to
rated load. Using light or no load for extended
periods of time may cause wetstacking or engine damage.
If a remote device connected to Remote
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays average weld amperage and then
defaults to preset amperage.
Receptacle is faulty or is disconnected
during operation, the meters display
CHEK REMT (see Section 8-13). Clear
fault by stopping and restarting the unit or
by turning Process/Contactor switch to
another position.
To Start:
NOTICE − Do not use ether or other starting
fluids. Using starting fluids voids warranty.
6
If engine does not start, let engine come
See Section 6-3 for Process/Contactor
switch information.
to a complete stop before attempting restart.
Above 325F (05C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325F (05C): turn engine control switch
to Run position. Push Preheat switch up for 6
seconds. Turn Engine Control switch to Start.
Release Engine Control switch and Preheat
switch when engine starts.
Do not operate Preheat switch for more
than 20 seconds at a time.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges, Meters, And Lights
See Section 6-13 for complete fuel, hour,
and engine shutdown information.
3
Fuel Gauge
Use gauge to check fuel level.
7
Process/Contactor Switch
Adjust Control/Select Button
Adjust Control
With Process/Contactor Switch in any SMAW
or GTAW process, turn Adjust control to adjust preset amperage. With Process/Contactor switch in any FCAW or GMAW process,
turn Adjust control to adjust preset voltage.
Select Button
Push the control to use as Select button.
To access Arc Control setting, push and
hold Adjust control for 1 second, then release. Rotate counterclockwise to set
softer arc control. Rotate clockwise to set
stiffer arc control. Push Adjust control in
and release to save Arc Control setting.
Arc Control setting will time out after 5
seconds of inactivity.
To access Service Menu, push and hold
Adjust control for 5 seconds, then release. See Section 6-4 for Service Menu
DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
10 Arc Control Meter
Displays current Arc Control setting. Default
value for all processes is 0. Arc Control settings adjust: DIG for SMAW processes, Auto
Stop for GTAW processes, and inductance
for FCAW and GMAW processes. For softer
settings, the LEDs to the left of the star illuminate. For stiffer settings, the LEDs to the right
of the star illuminate. No Arc Control settings
are accessible for GTAW Remote and CAC-A
processes. See Section 6-5.
Other Receptacles
11 USB Receptacle
Allows software updates from a USB drive
(see Section 6-11). A summary file of recoded
data from the unit will be saved to a USB drive
that is inserted (see Section 6-12).
Indicator Lights
12 Setup Light
Illuminates when in the Service Menu.
13 In Use Light
Illuminates when connected to an ArcReach
accessory.
14 Arc Control Light
Illuminates when in the Arc Control settings.
OM-281496 Page 31
Complete Parts List is available at www.MillerWelds.com
6-3. Process/Contactor Switch
1
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor switch is in an Output
On position and the engine is
running.
Use switch to select weld process
and weld output on/off control (see
table below).
Place switch in Remote On/Off
positions to turn weld output on and
off with a device connected to the
Remote receptacle.
Place switch in Output On positions
for weld output to be on whenever
the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Section
6-8).
Ref. 277091-A
REMOTE ON/OFF
OUTPUT ON
Process/Contactor Switch Setting
Typical Process Applications (DC Only)
Output On – GMAW/FCAW (MIG)
MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not
require a control cable back to the welder/generator.
Output On – FCAW-S (Electrode
Negative)
FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that
does not require a control cable back to the welder/generator.
Output On − SMAW (STICK XX18
and STICK XX10)
Stick welding with or without a remote amperage control. Strike an arc to start welding.
Output On – GTAW (Lift-Arc TIG)
Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
welder/generator to aid arc start. Can be used with or without a remote control. Auto
Crater option can be enabled/disabled using the Service Menu (see Section 6-4).
Output On – CAC-A (Air Carbon Arc
Gouging)
Gouging with or without a remote amperage control. Strike an arc to start gouging.
Remote ON/OFF - GTAW (Remote
TIG)
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote control allows remote On/Off and Amperage control. Another typical application is a
simple TIG rig with a remote control device.
Remote ON/OFF - SMAW (Remote
Stick)
Stick welding with remote with contactor control allows remote On/Off and Amperage
control. This can help eliminate accidental arc strikes.
Remote ON/OFF - GMAW/FCAW
(Remote MIG)
MIG solid wire and dual shield flux core using a constant speed feeder. Use feeders with
14-pin remote voltage control, or use a Spoolmatic 30A with WC24 control.
OM-281496 Page 32
Complete Parts List is available at www.MillerWelds.com
6-4. Service Menu
1
Adjust Control/Select Button
Press and hold control for 5 seconds,
then release to access the Service
Menu. Rotate the knob to scroll
through the menu items. Press and
release the control to access the options and information within each
menu item.
1
Rotate the control counterclockwise
to decrease the value or select NO/
OFF. Rotate the control clockwise to
increase the value or select YES/
ON.
Press and release control to save selection. After 5 seconds of inactivity,
the menu will time out and the selection will not be saved.
Menu Item
Selectable Item
Option(s)
Description
HOT STRT
LIMT OFF
Disables Hot Start option.
(Only accessible in SMAW
processes)
LIMT 1.25
Sets Hot Start current limit, selectable between 1.25 and 2.0 (0.25 increments) in
SMAW XX10 and SMAW Remote.
LIMT 1.50
Sets Hot Start current limit, selectable between 1.5 and 3.0 (0.5 increments) in
SMAW XX18.
AUTO CRTR
ATCR ON
Enables Auto Crater option.
(Only accessible in GTAW
processes)
ATCR OFF
Disables Auto Crater option.
DIG RNGE
50 - 150
HOUR MTR
−−
Displays engine hours.
OIL HOUR
−−
Displays remaining oil change hours before service is due.
OIL SET
50 HRS
Sets the starting hours for oil change period. Selectable from 50−1500 hours in
50 hour increments.
OIL RSET
RSET YES
Resets oil change period to selected value. Unit is set to factory recommended
period per engine manufacturer.
RSET NO
Oil change remaining hours do not reset.
VRD ON
Enables VRD (Voltage Reducing Device) option, lowering open-circuit voltage.
VRD OFF
Disables VRD (Voltage Reducing Device) option.
SOFT WARE
−−
Displays the current revision of firmware installed.
FACT RSET
RSET YES
Resets all settings to factory defaults.
RSET NO
All settings remain at previous settings.
VRD
Sets current limit above preset amperage between 50 and 150 amps.
OM-281496 Page 33
Complete Parts List is available at www.MillerWelds.com
6-5. Arc Control Settings
Arc Control is not active when the Process/Contactor switch is in the following positions:
Electrode Hot − CAC-A (Air Carbon Arc Gouging)
Remote ON/OFF GTAW (Remote TIG)
Miller recommends Hobart filler metals.
Process/Contactor Switch
Arc Control
SOFT
Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT
-12
(0)
Starting point for mild steel wire
STIFF
(1 to 25)
Starting point for aluminum wire (low inductance)
STIF
12
Voltage sensing feeder
SOFT
Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)
(0)
Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes
STIFF
(1 to 25)
Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13
electrodes. Also for pipe welding with XX10 and XX18 electrodes
STOP
(−5 to −1)
Auto-Crater off (see Section 6-4). More sensitive Auto-Stop
(0)
Starting point.
STOP
(1 to 5)
Less sensitive Auto-Stop
Lift-Arc start. No Auto Crater allows full control on pipe welds with
short or long arc length. Auto Stop feature allows arc to be broken
without loss of shielding gas.
STOP
(−5 to −1)
Auto Crater on (see Section 6-4). More sensitive Auto-Crater
initiation
(0)
Starting point
STOP
(1 to 5)
Less sensitive Auto-Crater initiation
SOFT
(−25 to −1)
(0)
STIFF
(1 to 25)
OM-281496 Page 34
Starting point
Complete Parts List is available at www.MillerWelds.com
Process/Contactor Switch
Arc Control
SOFT
Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT
-12
(0)
Starting point for mild steel wire
STIFF
(1 to 25)
Starting point for aluminum wire (low inductance).
STIF
12
Starting point for dual shield flux core, vertical overhead
Wire feeder connects to
Remote receptacle
STIF
25
6-6. Dynamic Dig Settings
Process/Contactor Switch
Arc Control
SOFT
Starting point for 3/32 rod
(−25 to −1)
SOFT
-15
(0)
Starting point for XX10 electrode/open root vertical down joint
STIFF
(1 to 25)
Stiffer, more rapidly responding arc
Dig Range
DIG
(50)
Starting point for 3/32 rod
(100)
Starting point for downhill pipe (factory default)
DIG RNGE
DIG RNGE
65
115
(150)
Arc Control
SOFT
Flat or horizontal welds with XX18 electrode or 3/32 rod with short
(−25 to −1) weld cables
SOFT
(0)
-15
Starting point for XX10, XX11, XX13, XX14, XX24, and XX22
electrodes
STIFF
(1 to 25)
Dig Range
DIG
(50)
Starting point for 3/32 rod
DIG RNGE
65
DIG RNGE
75
Starting point for XX18 electrode
(100)
Starting point for downhill pipe (factory default)
DIG RNGE
115
(150)
OM-281496 Page 35
Complete Parts List is available at www.MillerWelds.com
6-7.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
1
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted too high. If
electrode sticks to workpiece, use a
quick twist to free it.
2
3
6-8. Lift-Arct TIG With Auto-Stopt And Auto-Cratert
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc
1
Select Lift-Arc at Process/Contactor switch.
2
Turn gas on.
1
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Auto-Stop
1
2
3
See
Section 6-4 to adjust
Auto-Stop and Auto-Crater.
Arc End With Auto-Stop:
1
2
3
While welding.
Lift torch to start Auto-Stop.
Arc stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
Arc End With Auto-Crater:
OR
Remote control is not needed
when using Auto-Crater.
Arc End With Auto-Crater
1
2
3
4
1
2
3
4
While welding.
Lift torch slightly to start
Auto-Crater end (current is
reduced).
Lower torch. Weld current
ramps down.
Shielding gas continues until
shut off.
Miller
recommends Hobart
filler metals.
WM Marketing
OM-281496 Page 36
Complete Parts List is available at www.MillerWelds.com
6-9. Voltage/Amperage Control With 14-Pin Remote Accessory
1
Remote Receptacle
Connect optional remote control to
receptacle (see Section 5-12).
When a remote control is con-
nected to the Remote receptacle, the Auto Remote Sense
feature automatically switches
voltage/amperage control to the
remote control. When a device
is connected to the Remote receptacle, remote voltage/amperage control is always available regardless of the position of
the Process/Contactor switch.
1
2
3
2
3
In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
Connect Remote
Control To Remote
Receptacle
56
205
Turn Remote Control On. Adjust Optional Remote
Control to 100%
Voltmeter
Ammeter
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding
Set V/A Control
To Desired Maximum
Weld Output Using Weld
Meters
Set TIG or STICK Process
Voltmeter Toggles Between
Preset And Actual Output
When Not Welding, Actual
Voltage While Welding
28
0
Ammeter Shows Zero
Min
(20 A DC)
Max (205 A DC)
Adjust Optional Remote
Control to desired
weld output
Turn Remote Control On.
Adjust Optional Remote
Control to desired
weld output
Connect Remote
Control To Remote
Receptacle
Weld meters show preset
output when not welding.
Set WIRE Process
0774 / Ref.263 482-A / Ref. 263 482-B
OM-281496 Page 37
Complete Parts List is available at www.MillerWelds.com
6-10. Operating Engine Block Heater
1
Engine Block Heater Plug
Use heater to maintain a constant
engine coolant temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
CAT
Heater Specifications
Watts
Volts ±10%
1000
120
!
NOTICE − In extremely cold weather, heater should be connected to
power source when engine is
warm.
!
Kubota
Heater Specifications
Watts
Volts ±10%
400
120
Do not run engine while engine block heater is on.
The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.
1
Coolant heater1 2018−01
Notes
OM-281496 Page 38
Complete Parts List is available at www.MillerWelds.com
6-11. Updating Software
Obtain the latest firmware to be loaded
from MillerWelds.com.
Copy the desired firmware to an approved
USB flash drive (see Section 9-1).
With the machine turned off, insert the
flash drive into the USB receptacle on the
front of the machine. Turn the Engine Control switch to the Run or Run/Idle position.
Do not start the engine.
When the machine has powered up, if valid
files exist on the flash drive, the user is
prompted to confirm the start of the download. The Voltmeter/Ammeter display
reads: AL? NO.
Confirm by rotating the Adjust Control/Select button clockwise to select YES. Then
press the Select button.
After the update has started, do not
power down or remove the flash drive
until the update is complete.
During the download, the left meter display
indicates the active download with ALLC,
ALLW, AL C, or AL W. The right meter display indicates the percentage of the download completed with a number from 0 to
100.
When the update has completed successfully, the machine restarts.
Failures are indicated on the meter display.
Correction of failed updates depends on
what type of failure occurred.
OM-281496 Page 39
Complete Parts List is available at www.MillerWelds.com
6-12. Summary File
1
1
Summary File
Each time a USB stick is inserted
in the USB receptacle, a summary file is saved to the USB stick as
SummaryFile.txt.
“USB ACC” will display as the file
is written. File is complete when
display no longer shows “USB
ACC.”
The summary file provides diagnostic and weld information.
OM-281496 Page 40
Complete Parts List is available at www.MillerWelds.com
6-13. Fuel/Hour Gauge Descriptions
OM-281496 Page 41
Complete Parts List is available at www.MillerWelds.com
6-14. Associating ArcReach Devices (ArcReach Models Only)
!
Stop engine.
NOTICE − Do not exceed machine duty cycle.
Associating ArcReach Device To Engine Driven Welder/Generator
Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection
diagrams.
The welder/generator has the ability to associate automatically with an ArcReach device at power up. The Process/Contactor switch must
be set to an Output ON mode to associate with an ArcReach device.
See the ArcReach device Owner’s Manual to associate the device to the welder/generator.
When the association process is complete, the In Use light will be illuminated. Depending on the capabilities of the ArcReach device, the
Process/Contactor switch, Adjust Control/Select button, and Arc Control adjustment may be overridden.
The following ArcReach accessories are compatible with this welder/generator:
ArcReach Stick/TIG Remote
ArcReach SuitCase Feeders
ArcReach Smart Feeder
For Stick Or TIG Welding
For MIG Or FCAW Welding
For Advanced Wire Processes
When welder/generator is associated
with Stick/TIG Remote:
SMAW processes: Amperage,
Electrode Type, and Arc Control
settings are adjusted on the remote.
GTAW and CAC-A processes:
Amperage settings are adjusted on the
remote.
When welder/generator is associated
with Suitcase X-TREME ArcReach
feeder, voltage and wire feed settings
are adjusted on the feeder.
When welder/generator is associated
with Smart Feeder, all controls switch
to the feeder, and the display reads
SMRT ACC.
When using an ArcReach device,
engine
speed
weld/power speed.
is
always
274460-A / 266206-D
OM-281496 Page 42
Complete Parts List is available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Auxiliary Power Receptacles
1
2
3
7
6
4
5
265 602-A
!
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power life
support equipment.
!
Unplug power cord before attempting to service accessories or tools.
1
220V 16A AC Receptacle RC11
2
110V 20 A AC Receptacle GFCI1
3
220V 32 A AC Receptacle RC12
Receptacles supply 50/60 Hz single-phase
power.
Maximum combined output of all receptacles is 10 kVa/kW.
4 Earth Leakage Circuit Breaker ELCB1
ELCB1 protects receptacle RC11 from
overload and earth leakage fault. If circuit
breaker opens, the receptacle does not
work. Place switch in On position to reset
circuit breaker.
5 Earth Leakage Circuit Breaker ELCB2
ELCB2 protects receptacle RC12 from
overload and earth leakage fault. If circuit
breaker opens, the receptacle does not
work. Place switch in On position to reset
circuit breaker.
6 Supplementary Protector CB5
CB5 protects the stator windings from overload. If supplementary protector opens, the
receptacles do not work. Reduce load and
place in On position.
7 Supplementary Protector CB4
CB4 protects GFCI1 from overload. If supplementary protector opens, the receptacle
does not work. Press button to reset.
!
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
At least once a month, run engine at weld/
power speed and press test button to
verify ELCBs are working properly.
If a supplementary protector or circuit
breaker continues to open, contact
Factory Authorized Service Agent.
Generator power decreases as weld
output increases.
OM-281496 Page 43
Complete Parts List is available at www.MillerWelds.com
7-2. GFCI Receptacle Information, Resetting, And Testing
Alternate
location for red
and green indicator LEDs.
1
2
5
4
3
Orientation of receptacle may be different in other applications.
RotGFCI1 2018-01
!
!
1
2
3
4
5
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
Unplug power cord before attempting to service accessories or tools.
120 V 20 A AC GFCI Receptacle
GFCI Receptacle Test Button
GFCI Receptacle Reset Button
Red GFCI Indicator Light (LED)
Green GFCI Indicator Light (LED)
Red and Green indicator lights may be
combined in a single LED.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
OM-281496 Page 44
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place ignition switch in RUN
position, and press GFCI Reset button. Reconnect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Resetting/Testing GFCI Receptacle
Testing GFCI Receptacles
!
Test GFCI monthly.
!
Start engine and press the GFCI Test button. The GFCI Reset button should pop out.
If Red LED blinks, stop using GFCI
receptacle and have it replaced by a
Factory Authorized Service Agent.
Press the GFCI Reset button.
!
Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
Complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. CAT Maintenance Label
237 382-J
OM-281496 Page 45
Complete Parts List is available at www.MillerWelds.com
8-2. Kubota Maintenance Label
j
287 061-F
OM-281496 Page 46
Complete Parts List is available at www.MillerWelds.com
8-3. Routine Maintenance
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Stop engine before maintaining.
See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Every
8
Hours
Section 5-5,
5-6, and 5-8
See engine manual for fuel
specifications.
Coolant Level
Fuel Level
See engine manual for oil
specifications.
Clean unit exterior, including stainless steel, frequently to prevent rust and
corrosion.
Oil Level
Oil, Fuel Spills
Every
100
Hours
Section 8-4
Battery & Weld Terminals
Air Cleaner Hoses
Every 250 Hours
Air Cleaner Element
Unreadable Labels
Engine
Manual,
Section 8-6,
8-12
1/2 in.
(13 mm)
NOTICE − Change engine oil and filter
after initial 50 to 75 hours of use.
Oil Oil Filter
Fan Belt Tension
Every
500
Hours
Spark Arrestor
Kubota
FUEL
Section
5-11, 8-12
SLUDGE
Weld Cables
Radiator Thermostat
Every
1000
Hours
Fuel Filter
Kubota Sediment Filter
Drain Sludge
Section 5-8,
8-7, and
Engine
Manual
OR
Slip Rings*
Brushes*
Valve Clearance*
Inside Unit
Radiator Fluid Level
Every
2000
Hours
Injectors*
Caterpillar Corporate Headquarters
100 North East Adams Street
Peoria, Illinois USA 61629
(309) 675−1000
http://www.cat.com/engines
Cat Dealer Locator:
Use website to find local engine service facility.
Kubota Engine America
505 Schelter Road
Lincolnshire, IL 60069
Phone: 847-955-2500 Fax: 847-955-2699
To find a service facility near you, contact the
KEA distributor in your area:
http://www.kubotaengine.com
OM-281496 Page 47
Complete Parts List is available at www.MillerWelds.com
8-4. Servicing Air Cleaner
!
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
4
1
2
NOTICE − If you decide to clean the primary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
the safety element after servicing the primary element three times.
3
Optional
1
2
5
6
7
3
4
8
Intake Manifold
Service Indicator (Optional,
Customer Supplied)
Service Indicator Window
Service Indicator Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Optional
9
5
Housing
6
Safety Element (Optional)
7
Primary Element
8
Cover
9
Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove element(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.
Keep nozzle
2 in (51 mm)
from element.
!
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Blow
Inspect
Reinstall primary element and cover
(dust ejector down).
aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-281496 Page 48
Complete Parts List is available at www.MillerWelds.com
8-5. Checking Generator Brush Assembly
!
Stop engine and let cool.
1
Generator Brush Assembly
Mark and disconnect leads at brushholder assembly. Remove assembly. Press
on brush to be sure springs compress.
1
Replace assembly if
brushes are damaged.
1
Replace assembly if brushes are damaged or if brush material is at or near
minimum length. Check length from
brushholder surface.
New Length:
5/8 in. (16mm)
Minimum Length:
1/4 in. (6.5mm)
GenBrush2 2018-01 / Ref 205725
8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler
!
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
!
3
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in.
2
803 582 / Ref. 245 609
OM-281496 Page 49
Complete Parts List is available at www.MillerWelds.com
8-7. Servicing Engine Cooling System
!
Stop engine and let cool.
1
Radiator Cap Cover
2
Radiator Draincock
3
Coolant Recovery Tank
Change coolant according to engine
manual. Add coolant according to engine
maintenance label.
1
Check coolant level in recovery tank
daily. If necessary, add coolant to recovery tank until coolant level is between
Cold Full and Hot Full levels. If recovery
tank coolant level was low, also check
coolant level in radiator when cold. Add
coolant if level is below bottom of radiator
filler neck.
2
3
Coolant1 2018−01 / Ref. 907427-6
8-8. Battery Maintenance
Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open-circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.
Notes
OM-281496 Page 50
Complete Parts List is available at www.MillerWelds.com
8-9. CAT Engine Speed Adjustment
!
Stop engine and let cool.
Engine Speed Adjustment
After tuning engine, check engine speed with tachometer or
frequency meter. See table for
proper no load speed. If necessary, adjust speed as follows:
NOTICE − Start engine and run
until warm. Maximum no load
speed must be set with engine
warmed up.
Turn Process/Contactor switch
to Stick − Weld Terminals Always On position.
4
1
Throttle Rod / Plunger
2
Lock Nut
3
Rubber Boot
4
Adjustment Screw
Adjustment screw is not used to
adjust engine speed when automatic idle option is installed.
To
prevent solenoid damage, be sure a 1/8 in. (3 mm)
gap exists between the engine low speed screw and
throttle lever when the solenoid is held in the energized
position.
Engine Speed
(No Load)
1890 rpm max
(63 Hz)
1500 rpm
(50 Hz)
Unhook rubber boot from the solenoid housing but leave connected to plunger.
Loosen lock nut. Place Engine
Control Switch in Auto position.
Turn throttle rod and plunger until engine runs at idle speed.
Tighten lock nut.
2
Hook rubber boot back onto solenoid housing.
Be
sure solenoid plunger
pulls all the way in (“bottoms”) when energized.
1
Weld/Power Speed
Adjustment
Weld/power speed
adjustment must be done by the
engine manufacturer’s factory authorized service
agent.
Tampering with adjustments
other than shown may affect
engine warranty.
!
Stop engine.
3
803 563
OM-281496 Page 51
Complete Parts List is available at www.MillerWelds.com
8-10. Kubota Engine Speed Adjustment
Engine Speed
(No Load)
1890 RPM max
(63 Hz)
1500 RPM
(50 Hz)
3
4
1
5
Stop
3
Tools Needed:
!
2
2
Low Speed Adjustment Screw
Engine speed is factory set and should not
require adjustment. After tuning engine,
check engine speed with tachometer or frequency meter. See table for proper no load
speed. If necessary, adjust speed as follows:
3
4
Lock Nut
Throttle Solenoid Rod
Start engine and run until warm.
Low speed adjustment screw is not used to
adjust engine speed when automatic idle
option is installed. To prevent solenoid damage, be sure a 1/8 in. (3 mm) gap exists between the engine low speed screw and the
Stop engine and let cool.
Turn Process/Contactor switch to Stick −
Weld Terminals Always On position.
1 High Speed Adjustment Screw
OM-281496 Page 52
Loosen nut. Turn high speed adjustment
screw until engine runs at weld/power
speed. Tighten nut.
throttle lever when the solenoid is held in
the energized position.
Adjust length of the throttle solenoid rod until engine runs at idle speed.
Do not set engine speed higher than
specified.
5 Engine Stop Lever
Use lever to stop engine.
!
Stop engine.
Close door.
Complete Parts List is available at www.MillerWelds.com
8-11. Overload Protection
!
Stop engine.
When a circuit breaker, supplementary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1
Fuse F1
F1 protects the stator exciter winding
from overload. If F1 opens, weld and
generator power is low or stops
entirely.
2
3
Circuit Breaker CB1 (Not
Shown)
Supplementary Protector CB2
4
Supplementary Protector CB3
5
Supplementary Protector CB8
6
Circuit Breaker CB9
CB1 protects the engine battery circuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring harness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
1
3
6
Press button to reset supplementary
protector.
CB9 protects the throttle solenoid
against overload. If CB9 opens, the
engine does not automatically idle
down. Check the linkage and solenoid. CB9 automatically resets.
4
5
OM-281496 Page 53
Complete Parts List is available at www.MillerWelds.com
8-12. Servicing Fuel And Lubrication Systems
!
Stop engine and let cool.
!
After servicing, start engine and
check for fuel leaks. Stop engine, tighten connections as
necessary, and wipe up spilled
fuel.
1
2
3
4
5
6
7
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
Primary Fuel Filter
Secondary Fuel Filter
Fuel Tank Sludge Drain Valve
Fuel Filter Clamps
To change oil and filter:
Route oil drain hose and valve through
hole in base. See engine manual and
engine maintenance label for oil/filter
change information.
6
2
Tools Needed:
CAT Engine
4
3
7
5
7
1
803 563 / Ref 214 777−E
OM-281496 Page 54
Complete Parts List is available at www.MillerWelds.com
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new
filter.
Kubota Engine
4
Install new filter and turn clockwise.
3
Bleed air from fuel system according to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
7
See engine manual.
To replace secondary fuel filter:
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter , reconnect fuel lines,
and reinstall clamps.
5
7
To drain sludge from fuel tank:
1
!
Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dispose of drained fuel in an environmentally safe manner.
Do not leave unit unattended
while draining fuel tank.
!
Properly lift unit and secure
in a level position. Use adequate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open sludge
drain valve. Close valve when
sludge has drained. Remove hose.
Close door.
803 581 / 907 427−6
OM-281496 Page 55
Complete Parts List is available at www.MillerWelds.com
8-13. Voltmeter/Ammeter Error Displays
IGBT
TEMP
Display Example
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions.
When an error is displayed, normally weld output has stopped but generator power output may be okay.
To reset error displays, stop unit and then restart. See below to reset CHEK REMT display.
Error Display
Description
CHEK REMT
Indicates a remote device connected to the Remote Receptacle may be faulty. CHEK REMT is also displayed whenever a
remote device has been connected to the Remote Receptacle and then disconnected. Clear fault by stopping and restarting
the unit, or by turning Process/Contactor switch to another position. If problem continues, have Factory Authorized Service
agent check the remote device and main control board PC1.
IGBT 1SHT
Indicates the thermistor in IGBT module 1 has shorted. Have Factory Authorized Service Agent check unit.
IGBT 1OPN
Indicates the thermistor in IGBT module 1 is open. Have Factory Authorized Service Agent check unit.
IGBT 2SHT
Indicates the thermistor in IGBT module 2 has shorted. Have Factory Authorized Service Agent check unit.
IGBT 2OPN
Indicates the thermistor in IGBT module 2 is open. Have Factory Authorized Service Agent check unit.
IGBT TEMP
Indicates an IGBT module has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle.
Keep engine access door closed when running unit to maintain proper cooling airflow past module. Allow unit to cool before
restarting. If problem continues, have Factory Authorized Service Agent check unit.
MAX POWR
Engine power limit exceeded, causing weld output to be temporarily reduced. Error clears after 5 seconds.
S/W ERR
Software version mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service
Agent check unit.
S/W BLD
Software build mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service Agent
check unit.
8-14. Troubleshooting Tables
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-13).
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles.
On/Off Switch Required position and turn remote contactor on (see Section 5-12).
Reset supplementary protector CB8 (see Section 8-11). Check for faulty remote device connected to Remote receptacle.
Check and secure connections to Remote receptacle (see Section 5-12).
Check Voltmeter/Ammeter error displays (see Section 8-13).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB3. (see Section 8-11).
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.
Check Voltmeter/Ammeter error displays (see Section 8-13).
Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit.
OM-281496 Page 56
Complete Parts List is available at www.MillerWelds.com
Trouble
Erratic weld output.
Remedy
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.
No remote fine amperage control.
Repair or replace remote control device.
Check and secure connections to Remote receptacle (see Section 5-12).
No 24 volt AC output at Remote Reset supplementary protector CB8 (24 volt) (see Section 8-11).
receptacle.
B. Generator Power
Trouble
Remedy
No generator power output at AC recept- Reset receptacle supplementary protector(s) (see Section 7-1). Check and reset GFCI receptacle if neacles; weld output okay.
cessary (see Section 7-2).
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check
field excitation circuit.
Reset supplementary protector CB3 (see Section 8-11).
Check Voltmeter/Ammeter error displays (see Section 8-13).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC Have Factory Authorized Service Agent check field excitation circuit.
receptacles.
Low output at generator power AC Check engine speed, and adjust if necessary.
receptacles.
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.
C. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-11).
Have Factory Authorized Service Agent check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-11).
Check engine wiring harness plug connections.
Check Voltmeter/Ammeter error displays (see Section 8-13).
Have Factory Authorized Service Agent check Engine Control switch S1 and control relay CR2.
Engine cranks but does not start.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel
pump.
Air in fuel system. See engine manual.
OM-281496 Page 57
Complete Parts List is available at www.MillerWelds.com
Trouble
Engine hard to start in cold weather.
Remedy
Use Preheat switch (see Section 6-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-3).
Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-7 ).
Check Voltmeter/Ammeter error displays (see Section 8-13).
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section
8-11). Reset supplementary protector CB2 (see Section 8-11). Have Factory Authorized Service
Agent check engine alternator, engine harness, fuel solenoid FS1, and the fuel pump.
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, fuel solenoid FS1, and the fuel pump.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check Voltmeter/Ammeter error displays (see Section 8-13).
Check engine air and fuel filters (see Sections 8-4 and 8-12).
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed.
Have Factory Authorized Service Agent check current transformer CT1 and current transducer HD1.
Engine does not run at idle speed.
Have Factory Authorized Service Agent check control relay CR4, circuit breaker CB9, and throttle
solenoid TS1.
Check Voltmeter/Ammeter error displays (see Section 8-13).
Check Voltmeter/Ammeter error displays (see Section 8-13).
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11).
wetstacking occurs.
OM-281496 Page 58
Complete Parts List is available at www.MillerWelds.com
SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . . . . . . . . . . . . 276418 . . USB Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F1 . . . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 217686 . . Belt, Alternator (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 244290 . . Brushholder Assembly, Generator w/Leads . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 274427 . . Kit, Filter Cat (C1.5) Perkins (403−15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202166 . . . . Filter, Oil (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 273865 . . . . Filter, Fuel In−line 5/16x5/16 Mic 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 217687 . . . . Filter, Fuel Spin−on (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 218468 . . Belt, Alternator (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 233482 . . Kit, Fuel Sedimenter (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 253901 . . Kit, Filter (Kubota) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 196428 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 207715 . . . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦197679 . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, 12V 570 Crk 100 Rsv Gp 35 Low Main . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-281496 Page 59
SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram − Models With CAT Engine
OM-281496 Page 60
281494-B
OM-281496 Page 61
Figure 10-2. Circuit Diagram − Models With Kubota Engine
OM-281496 Page 62
276789-D
OM-281496 Page 63
SECTION 11 − RUN-IN PROCEDURE
run_in1 2014−09
NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
11-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1
Welder/Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
2
NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/generator is kept loaded during run-in.
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
1
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.
OM-281496 Page 64
11-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
1
7
4
3
5
+
6
S-0683 / S-0684
!
Stop engine.
!
Do not touch hot exhaust pipe, engine parts, or load bank/grid.
!
Keep exhaust and pipe away from
flammables.
NOTICE − Do not perform run-in
procedure at less than 20 volts weld output
and do not exceed duty cycle or equipment
damage may occur.
1 Load Bank
Turn all load bank switches Off. If needed,
connect load bank to 115 volts ac wall
receptacle or generator auxiliary power
receptacle.
2 Welder/Generator
Place A/V range switch in maximum position, A/V control in minimum position, and
Output Selector switch (if present) in either
DC position.
3 Weld Cables
4 Resistance Grid
Use grid sized for generator rated output.
Turn Off grid.
5
Voltmeter
6 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several minutes.
For Load Bank
Set load bank switches and then adjust
generator A/V control so load equals
rated voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manual).
For Resistance Grid
Set grid switches and then adjust generator A/V control so load equals rated
voltage and current of the generator
(see nameplate, rating label, or the
specifications section in this manual).
Check generator and meters after first five
minutes then every fifteen minutes to be
sure generator is loaded properly.
NOTICE − Check oil level frequently during
run-in; add oil if needed.
It is recommended to run the welder/generator for two hours minimum and up to four
hours under load. Place A/V control in
minimum position, then shut down load
bank or grid to remove load. Run engine
several minutes at no load.
!
Stop engine and let cool.
7
Engine Exhaust Pipe
Repeat procedure if wetstacking is present.
OM-281496 Page 65
SECTION 12 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown.
12-1. Selecting Equipment
1
2
1
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
!
2
Do not use 2-prong plug unless equipment is double
insulated.
3
OR
gen_pwr 2018−06 − ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
OM-281496 Page 66
3
Metal Vehicle Frame
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
!
Bed liners, shipping skids, and
some running gear insulate the
welder/generator from the vehicle
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
12-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
3
GND/PE
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
12-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive
load
and
requires
approximately six times more power
while starting the motor than when
running (see Section 12-8).
VOLTS 115
AMPS 4.5
Hz
50/60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its
running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-281496 Page 67
12-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10,550
15,900
23,300
8100
23,300
35,000
46,700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10,700
400
550
650
800
1100
12-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
Farm Duty Motors Std. (e.g. Conveyors, Feed
Augers, Air Compressors)
Farm Duty Motors High Torque
(e.g. Barn Cleaners, Silo Unloaders, Silo Hoists,
Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-281496 Page 68
Rating
Starting Watts
Running Watts
2 HP
1/3 HP
1000
1650
3400
4400
2900
10,500
1720
1000
650
1000
1400
1100
2800
720
1/2 HP
2575
975
3/4 HP
4500
1400
1/4 HP
1/2 HP
3/4 HP
1 HP
6100
1600
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
8200
10,550
15,900
23,300
8100
2200
2850
3900
6800
2000
6000
5 HP
23,300
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
1/2 HP
500 PSI
550 PSI
700 PSI
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
950
1400
1600
800
750
1000
800
1050
1/3 HP
1/2 HP
1/3 HP
1/2 HP
12-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in.
3/8 in.
1/2 in.
6-1/2 in.
7-1/4 in.
8-1/4 in.
9 in.
10 in.
14 in.
6 in.
8 in.
10 in.
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in.
2 HP, 14 in.
Standard 9 in.
Heavy Duty 12 in.
1/3 HP
18 in.
HID
Metal Halide
Mercury
Sodium
Vapor
400 GPH
900 GPH
3/4 HP, 16 in.
1 HP, 20 in.
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10,500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-281496 Page 69
12-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welder/generator amperage output
must be at least twice the motor’s
running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
12-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-281496 Page 70
12-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
4
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s
Manual and national, state,
and local codes.
!
Do not connect to any electrical distribution system
normally supplied by utility
power unless a proper transfer switch and grounding
procedure are employed.
Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
1 Utility Electrical Service
Essential
Loads
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welder/Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 12-4).
OM-281496 Page 71
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4 (25)
6 (16)
8 (10)
10 (6)
12 (4)
14 (2.5)
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4 (25)
8 (10)
10 (6)
12 (4)
14 (2.5)
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-281496 Page 72
6 (16)
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01
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